Conductive elements in cable jackets and separators

ABSTRACT

A cable, of the twisted pair or fiber optic type, includes conductors for permitting patch cord tracing between ports. In the case of a twisted pair cable, the conductors may be embedded within, or attached to a surface of, a separator. Alternatively, in the case of a twisted pair cable, the conductors may be embedded within, or attached to a surface of, a jacket. In the case of a fiber optic cable, the conductors may be located amongst strength members. Alternatively, in the case of a fiber optic cable, the conductors may be embedded within, or attached to a surface of, a jacket.

This application is a divisional of U.S. application Ser. No. 13/215,677filed Aug. 23, 2011, which claims the benefit of U.S. ProvisionalApplication No. 61/376,031, filed Aug. 23, 2010, the contents of eachapplication are herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to twisted pair cables having conductiveelements within or attached to a separator or a jacket wall. Moreparticularly, the present invention relates to communications patchingsystems, equipment and methods for automatically tracking connections incommunications networks, wherein the conductive elements within orattached to the separator or jacket wall are used to achieve thetracking between ports of a patch panel.

2. Description of the Related Art

The present application relates to the Assignee's prior applications,Ser. No. 12/545,096, filed Aug. 21, 2009, and Ser. No. 12/787,486, filedMay 26, 2010, each of which is incorporated herein by reference. Withreference to FIGS. 1 and 2, a brief description of the basic systemfound in the two above applications follows. The basic system describedin prior application Ser. Nos. 12/545,096 and 12/787,486 provides abackground understanding of the present invention, but should not beconsidered admitted prior art.

In the basic system shown in FIG. 1, a patch panel 700 has a first row720 of ports and a second row 730 of ports. A third row 600 ofelectrical contact pads is interposed between the first and second rows720 and 730 of ports. Electrical pads 621 and 622 correspond to upperport 721 and electrical pads 621′ and 622′ correspond to lower port 731.

FIG. 2 illustrates a patch cord 400 in accordance with the backgroundart. The patch cord 400 includes a first plug 420 at a first end of thepatch cord 400 and a second plug 420′ at a second end of the patch cord400. The first plug 420 includes first and second electrical contactpins X and Y. The second plug 420′ includes third and fourth electricalcontact pins X′ and Y′. The first pin X of the first plug 420 iselectrically connected to the third pin X′ of the second plug 420′ via afirst electrically conductive wire 409. The second pin Y of the firstplug 420 is electrically connected to the fourth pin Y′ of the secondplug 420′ via a second electrically conductive wire 410.

When the first plug 420 is inserted into the upper port 721, the firstand second pins X and Y make electrical contact with the electrical pads621 and 622, respectively. When the second plug 420′ is inserted in tothe lower port 731, the third and fourth pins X′ and Y′ make electricalcontact with the electrical pads 622′ and 621′, respectively. Theelectrical circuits formed by the pins X, Y, X′, Y′ and the pads 621,622, 621′, 622′ are used to determine the interconnection made by thepatch cord 400, such that a mapping of the patch cords, as connected tothe various ports of the patch panels, can be facilitated. Inparticular, a signal of approximately 10 KHz is transmitted through theformed electrical circuit and used by the mapping system to determinethe port-to-port connections. The mapping system is more fully describedin the above-two, incorporated-by-reference applications by the presentAssignee.

SUMMARY OF THE INVENTION

The Applicants have appreciated drawbacks with the related art. Theinternal construction of the patch cord 400 is best seen in the partialcut-away view in the middle of the patch cord 400 in FIG. 2. The firstand second wires 409 and 410 are intermixed amongst the twisted pairsand separator within the jacket 418 of the patch cord 400. Hence, thefirst and second wires 409 and 410 cause the cable size (e.g., diameter)to be increased.

It is an object of the present invention to address one or moredrawbacks associated with the related art.

These and other objects are accomplished by a cable, of the twisted pairor fiber optic type, which includes conductors for permitting patch cordtracing between ports. In the case of a twisted pair cable, theconductors may be embedded within, or attached to a surface of, aseparator. Alternatively, in the case of a twisted pair cable, theconductors may be embedded within, or attached to a surface of, ajacket. In the case of a fiber optic cable, the conductors may belocated amongst strength members. Alternatively, in the case of a fiberoptic cable, the conductors may be embedded within, or attached to asurface of, a jacket.

Further scope of applicability of the present invention will becomeapparent from the detailed description given hereinafter. However, itshould be understood that the detailed description and specificexamples, while indicating preferred embodiments of the invention, aregiven by way of illustration only, since various changes andmodifications within the spirit and scope of the invention will becomeapparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description given hereinbelow and the accompanying drawingswhich are given by way of illustration only, and thus, are not limits ofthe present invention, and wherein:

FIG. 1 is a perspective view of a section of a patch panel with plugsaligned for mating within ports of the patch panel, in accordance withthe background art;

FIG. 2 is a perspective view of a patch cord having the plugs of FIG. 1,in accordance with the background art;

FIG. 3 is a perspective view of a twisted pair cable with a star orplus-shaped separator with conductors, in accordance with a firstembodiment of the present invention;

FIG. 4 is a cross sectional view taken along line IV-IV in FIG. 3;

FIG. 5 is a cross sectional view of a twisted pair cable with a flattape separator with conductors, in accordance with a second embodimentof the present invention;

FIG. 6 is a perspective view of a twisted pair cable with a star orplus-shaped separator with conductors, in accordance with a thirdembodiment of the present invention;

FIG. 7 is a perspective view of a twisted pair cable with a flat tapeseparator with conductors, in accordance with a fourth embodiment of thepresent invention;

FIG. 8 is a cross sectional view of a twisted pair cable with a jacketwith conductors, in accordance with a fifth embodiment of the presentinvention;

FIG. 8P is a cross sectional view of a twisted pair cable with a jacketwith conductors, in accordance with a sixth embodiment of the presentinvention;

FIG. 9 is a cross sectional view of a twisted pair cable with a jacketwith conductors, in accordance with a seventh embodiment of the presentinvention;

FIG. 10 is a perspective view of a fiber optic cable with a jacket withconductors, in accordance with an eighth embodiment of the presentinvention;

FIG. 11 is a cross sectional view taken along line XI-XI in FIG. 10;

FIG. 12 is a cross sectional view of a fiber optic cable with strengthmembers with conductors, in accordance with a ninth embodiment of thepresent invention; and

FIG. 13 is a cross sectional view of joined fiber optic cables withstrength members with conductors, in accordance with a tenth embodimentof the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now is described more fully hereinafter withreference to the accompanying drawings, in which embodiments of theinvention are shown. This invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art.

Like numbers refer to like elements throughout. In the figures, thethickness of certain lines, layers, components, elements or features maybe exaggerated for clarity. Broken lines illustrate optional features oroperations unless specified otherwise.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention.Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the specification andrelevant art and should not be interpreted in an idealized or overlyformal sense unless expressly so defined herein. Well-known functions orconstructions may not be described in detail for brevity and/or clarity.

As used herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof. As used herein, the term “and/or”includes any and all combinations of one or more of the associatedlisted items. As used herein, phrases such as “between X and Y” and“between about X and Y” should be interpreted to include X and Y. Asused herein, phrases such as “between about X and Y” mean “between aboutX and about Y.” As used herein, phrases such as “from about X to Y” mean“from about X to about Y.”

It will be understood that when an element is referred to as being “on”,“attached” to, “connected” to, “coupled” with, “contacting”, etc.,another element, it can be directly on, attached to, connected to,coupled with or contacting the other element or intervening elements mayalso be present. In contrast, when an element is referred to as being,for example, “directly on”, “directly attached” to, “directly connected”to, “directly coupled” with or “directly contacting” another element,there are no intervening elements present. It will also be appreciatedby those of skill in the art that references to a structure or featurethat is disposed “adjacent” another feature may have portions thatoverlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”,“upper”, “lateral”, “left”, “right” and the like, may be used herein forease of description to describe one element or feature's relationship toanother element(s) or feature(s) as illustrated in the figures. It willbe understood that the spatially relative terms are intended toencompass different orientations of the device in use or operation inaddition to the orientation depicted in the figures. For example, if thedevice in the figures is inverted, elements described as “under” or“beneath” other elements or features would then be oriented “over” theother elements or features. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the descriptors ofrelative spatial relationships used herein interpreted accordingly.

FIG. 3 is a perspective view of an end of a cable 10 with a portion of ajacket 12 removed. The cable 10, in accordance with one embodiment ofthe present invention, is intended to replace the cable used in thepatch cord 400 of FIGS. 1 and 2. The jacket 12 surrounds first, second,third and fourth twisted pairs 16, 18, 20 and 22. A plus-shaped orstar-shaped separator 24 provides separation between the twisted pairs16, 18, 20 and 22. The benefits of a separator 24 are known in the artand include such things as internal crosstalk reduction.

FIG. 4 is a cross sectional view taken along line IV-IV in FIG. 3. Asseen in FIGS. 3 and 4, the wires 409 and 410, amongst the twisted pairsand separator in FIG. 2, have been eliminated. The electrical connectionbetween the pins X and X′ and between the pins Y and Y′ of the first andsecond plugs 420 and 420′ in FIG. 2 is now accomplished by first andsecond embedded wires A and B. The embedded wires A and B may be formedof copper, copper-clad steel, aluminum, or other conductive metals oralloys.

As best seen in FIG. 4, the embedded wires A and B are within the centersection of the separator 24. However, it should be appreciated that theembedded wires A and B may be located within one or more of the wings26, 28, 30 and 32 of the separator 24. In a preferred embodiment, theembedded wires A and B each have a size of about 30 to 38 AWG, morepreferably about 34 AWG.

FIG. 5 illustrates that the plus-shaped or star-shaped separator 24 maybe replaced with a flat or tape-shaped separator 100. In a preferredembodiment, the flat, tape separator 100 is about 10 to 20 mils inthickness (e.g., separates the first and second pairs 16 and 18 by about10 to 20 mils). More preferably, the flat, tape separator 100 has athickness of about 15 mils. The flat separator 100 separates the firstand fourth twisted pairs 16 and 22 from the second and third twistedpairs 18 and 20 and can be substituted for the plus-shaped separator(FIG. 4) in certain situations, while providing some benefits (e.g.,reduced cost, reduced cable size and weight per unit length, lower smokeduring a burn test).

As with the embodiment of FIGS. 3 and 4, the first embedded wire Aprovides an electrical connection between the first pin X of the firstplug 420 and the third pin X′ of the second plug 420′, while the secondembedded wire B provides an electrical connection between the second pinY of the first plug 420 and the fourth pin Y′ of the second plug 420′.

FIG. 6 is similar to FIG. 3, but illustrates an alternative cable 10′where the embedded first and second wires A and B are replaced by firstand second printed conductive wire traces C and D. As illustrated inFIG. 6, the traces C and D may be placed upon outer surfaces of wings 30and 26 of the plus-shaped separator 24′. Because the first throughfourth twisted pairs 16, 18, 20 and 22 are formed by insulated wires(e.g., insulation layer 44 over conductor 42 in the first twisted pair16), the conductive traces may be formed by the application of aflexible conductive material sprayed onto the wings 30 and 26 of theseparator 24′, and such layer will not interfere with the twisted wirepairs 16, 18, 20 and 22. Of course, a non-conductive coating may beapplied over the conductive traces C and D, if desired.

FIG. 7 is a view similar to FIG. 5, but illustrates an alternative flatseparator 100′ where the embedded first and second wires A and B arereplaced by first and second printed conductive wire traces C and D. Thejacket 12 of FIG. 7 houses only first and second twisted wire pairs 16and 18, as only two twisted pairs may be suitable in some patchingsituations. The traces C and D may be placed upon one surface of theflat separator 100′ in a spaced apart arrangement (as illustrated), orthe traces C and D may be placed upon opposing sides of the tape 100′.

FIG. 8 shows a modified cable 10″. The cable 10″ has a core (twistedpairs 16, 18, 20 and 22 and separator 24) in accordance with a typicaltwisted pair cable. The jacket 12′ has been modified. The jacket 12′ hasembedded therein, the first wire A and the second wire B.

The first and second wires A and B each have a size of about 30 to 38AWG, more preferably about 34 AWG. The electrical connection between thepins X and X′ and between the pins Y and Y′ of the first and secondplugs 420 and 420′ is accommodated by the first and second embeddedwires A and B. The embedded wires A and B may be formed of copper,copper-clad steel, aluminum, or other conductive metals or alloys.

In FIG. 8, the first wire A and the second wire B are located about 180degrees apart in the wall of the jacket 12′ to produce a mirrorsymmetrical cable construction, as is typical in the cabling arts.Applicants discovered that such a design performed suitably with shortpatch cord lengths, however with a patch cord length of 100 meters, the10 KHz signal sent through the first wire A and the second wire Bfailed. No useable signal was measured at the far end of the cable 10″.The failure was most likely due to a high impedance.

FIG. 8P is a cross sectional view of a preferred cable 10P. Applicantsdiscovered that by moving the placement of the first and second wires Aand B to about 30 degrees apart within the wall of the jacket 12′, the10 KHz signal could traverse the 100 meter patch cord length to permitthe port-to-port mapping system to function. The first and second wiresA and B were identically constructed, the only variation resided in thewire placement. Based upon these unexpected testing results, thepreferred embodiment of this configuration is to have the first andsecond wires A and B located less than 180 degrees apart in the wall ofthe jacket, such as in the range of 10 to 45 degrees, more preferably inthe range of 20 to 40 degrees, such as about 30 degrees apart.

FIG. 9 shows a modified cable 10′″. The cable 10′″ has a core (twistedpairs 16, 18, 20 and 22 and separator 24) in accordance with a typicaltwisted pair cable. The jacket 12″ has been modified. The jacket 12″ hasfirst and second printed conductive wire traces C and D on an innerradial surface thereof. The first printed conductive wire trace Cprovides the electrical connection between the pin X of the first plug420 and the pin X′ of the second plug 420′. The second printedconductive wire trace D provides the electrical connection between thepin Y of the first plug 420 and the pin Y′ of the second plug 420′. Aswith FIG. 8P above, the preferred embodiment has the first and secondconductive wire traces C and D located less than 180 degrees apart onthe wall of the jacket. FIG. 9 shows the first and second conductivewire traces C and D approximately 150 degrees apart. However, it isbelieved that the preferably embodiment or best mode of the inventionwould have the conductive wire traces C and D located less than 150degrees apart, such as in the range of 10 to 45 degrees, more preferablyin the range of 20 to 40 degrees, such as about 30 degrees apart.

FIGS. 10 and 11 above show a modified cable 10 f. The cable 10 f is afiber optic cable having a core including a single optical fiber 110,containing a core and a cladding layer surrounding the core. The opticalfiber 110 is surrounded and bonded to a coating or tight buffer layer120. A layer of loose tensile strength members 130, such as aramid yarn,surround the tight buffer layer 120. Finally, an outer jacket 140surrounds the strength members 130. The tight buffer layer 120 and theouter jacket 140 may be formed of polyvinyl chloride (PVC), or similarsuitable materials. The outer jacket 120 has embedded therein, the firstwire A and the second wire B.

The first and second wires A and B each have a size of about 30 to 38AWG, more preferably about 34 AWG. The electrical connection between thepins X and X′ and between the pins Y and Y′ of the first and secondplugs 420 and 420′ is accommodated by the first and second embeddedwires A and B. The embedded wires A and B may be formed of copper,copper-clad steel, aluminum, or other conductive metals or alloys. In apreferred embodiment, the first and second wires A and B are locatedless than 180 degrees apart in the wall of the jacket 140, such as inthe range of 10 to 45 degrees, more preferably in the range of 20 to 40degrees, such as about 30 degrees apart.

FIG. 12 is a cross sectional view similar to FIG. 11, but illustrates acable 10 f′ where the first wire A and the second wire B may beincorporated into the loose tensile strength members 130, such as aramidyarn. Other than the placement of the first wire A and the second wireB, the cable 10 f′ of the embodiment in FIG. 12 is the same as the cable10 f of the embodiment in FIGS. 10 and 11.

In the fiber patching environments, often times a duplex adapter isemployed. One fiber for the duplex adapter is used for transmission,while the other fiber of the duplex adapter is used for reception. Insuch circumstances and as illustrated in FIG. 13, the transmission andreception fibers often have their jackets joined by a web of jacketmaterial 101. Such a cable is known commercially as 1.6 mm Low SmokeZero Halogen Zipcord Cable, as embodied in product N-002-ZC-5L-F16AQ, asmanufactured by CommScope.

In this instance, it may be beneficial, in accordance with the presentinvention, to have the first wire A in the strength members 130 of onecable 10 f′″ and the second wire B in the strength members 130 of theother cable 10 f′″, as illustrated in FIG. 13.

The invention being thus described, it will be obvious that the same maybe varied in many ways. Such variations are not to be regarded as adeparture from the spirit and scope of the invention, and all suchmodifications as would be obvious to one skilled in the art are to beincluded within the scope of the following claims.

We claim:
 1. A cable comprising: a separator formed of a dielectricmaterial, dimensioned to at least separate a first twisted pair from asecond twisted pair within a cable core; and first and second electricalconductors embedded within, and completed surrounded by, said dielectricmaterial forming said separator.
 2. The cable of claim 1, wherein saidfirst and second electrical conductors extend continuously fromproximate a first end of said separator to proximate a second end ofsaid separator.
 3. The cable of claim 1, wherein said separator is agenerally star-shaped or plus-shaped member.
 4. The cable of claim 1,wherein said separator is a generally flat or tape-shaped member.
 5. Acable comprising: a separator formed of a dielectric material,dimensioned to at least separate a first twisted pair from a secondtwisted pair within a cable core; and first and second electricalconductors embedded within, or attached to an outer surface of, saidseparator, further comprising: a first plug attached to a first end ofsaid cable; and first and second electrical contact pins physicallyattached to said first plug, wherein said first and second contact pinsare electrically connected to said first and second electricalconductors.
 6. The cable of claim 5, further comprising: a second plugattached to a second end of said cable; and third and fourth electricalcontact pins physically attached to said second plug, wherein said thirdand fourth contact pins are electrically connected to said first andsecond electrical conductors.
 7. A cable comprising: an outer jacket;first, second, third and fourth twisted pairs of insulated conductorssurrounded by said outer jacket; a separator including a dielectricmaterial, dimensioned to separate said first twisted pair of insulatedconductors from said second twisted pair of insulated conductors along alength of said outer jacket; and first and second electrical conductorsembedded within, or attached to an outer surface of, said separator. 8.The cable of claim 7, wherein said separator is a generally star-shapedor plus-shaped member, separate from said outer jacket.
 9. The cable ofclaim 8, wherein said separator is dimensioned to separate said firsttwisted pair of insulated conductors from said third and fourth twistedpairs of insulated conductors along a length of said outer jacket, andsaid separator is dimensioned to separate said second twisted pair ofinsulated conductors from said third and fourth twisted pairs ofinsulated conductors along a length of said outer jacket, and saidseparator is dimensioned to separate said third twisted pair ofinsulated conductors from said fourth twisted pair of insulatedconductors along a length of said outer jacket.
 10. The cable of claim9, wherein said first and second electrical conductors are embeddedwithin said separator.
 11. The cable of claim 10, wherein said first andsecond electrical conductors are embedded within a center section ofsaid separator and each have a size of about 30 to 38 AWG.
 12. The cableof claim 9, wherein said first and second electrical conductors areattached to an outer surface of said separator.
 13. The cable of claim12, wherein said first and second electrical conductors are attached onwings of said separator and formed of a flexible conductive material.14. The cable of claim 7, wherein said separator is a generally flat ortape-shaped member, separate from said outer jacket.
 15. The cable ofclaim 14, wherein said separator separates said first and third twistedpairs of insulated conductors from said second and fourth twisted pairsof insulated conductors along a length of said outer jacket.
 16. Thecable of claim 15, wherein said separator has a thickness of about 10 to20 mils and wherein said first and second electrical conductors areembedded within said separator.
 17. The cable of claim 15, wherein saidfirst and second electrical conductors are attached to an outer surfaceof said separator.
 18. The cable of claim 17, wherein said first andsecond electrical conductors are attached to a same surface of saidseparator.